Footwear sole

ABSTRACT

A sole for an article of footwear having an insert with a plurality of forefoot support tubes are configured to control the support characteristics of the sole in a forefoot region of the sole. In one embodiment, the forefoot support tubes each include a base, and a wall extending from the base. The wall is formed from a material that has a lower durometer value than the base. In another embodiment, the forefoot support tubes are arranged in a radiating pattern, such that at least two of the forefoot support tubes diverge as they extend toward the lateral side of the insert.

BACKGROUND OF THE INVENTION

The present invention relates to footwear, and more particularly to asole construction for an article of footwear.

There is a continuing effort to provide ever more comfortable footwear.Running shoes, as well as other footwear, have undergone tremendousevolutionary advances in technology over the past 20 years. Many of thetechnological advances have occurred in the midsole. In most footwear,the midsole functions as the “suspension system” of the sole and itoften provides both protective cushioning and a stable platform for thewearer's foot. Variations in the characteristics of the midsole can havea dramatic affect on the performance of the shoe. In an effort toprovide improved performance, it is often desirable to vary the supportcharacteristics of the sole from one region to another. For example, itmay be desirable to provide a higher density material in the heel and alower density material in the forefoot. A higher density material in theheel provides greater support upon heel strike while a lower densitymaterial provides appropriate cushioning and support for the typicallysmaller loads encountered in the forefoot. A wide variety of soles havebeen developed to provide variable support over the foot. In someapplications, variable support is provided by forming different regionsof the midsole from different materials, such as softer EVA foam in theforefoot and firmer EVA foam in the heel. In other applications, thesole is provided with a support plate that can be configured to providethe sole with the desired overall support profile. Although a markedimprovement over conventional uniform sole constructions, there remainsa need for a sole construction that is inexpensive to manufacture andthat is highly tunable with a wide range of adjustability.

At the same time, there is also an ongoing effort to extend the life offootwear soles. In conventional footwear, the midsole (as well as othersole components) may begin to lose its performance over a relativelyshort period of time. Degradation of the sole material can cause thesole to lose its resiliency over time, particularly in regions of highand repeated impact, such as the heel. The rate of degradation will varyfrom sole to sole, but is largely dependent on the specificcharacteristics of the sole material and the types of loads applied tothe sole. For example, conventional closed and open cell foams, such asEVA, have a relatively short life as the material naturally breaks downover relatively short periods of use. Conventional foam materials arealso susceptible to temperature changes, which can cause the resiliencyof the foam to vary noticeably. For example, the sole may becomenoticeably stiffer in colder temperatures and noticeably softer inhigher temperatures. As a result, temperature can have a significantadverse affect on the support characteristics of a sole manufacturedfrom conventional foam materials.

Accordingly, there remains a need for a highly reliable, highly tunablesole that has an extended life and is relatively inexpensive tomanufacture.

SUMMARY OF THE INVENTION

The aforementioned problems are overcome by the present invention whichprovides a sole having an insert with a plurality of support tubes thatare tuned to provide the desired support profile. Each support tube mayinclude an internal web having an orientation that is selected toprovide the desired support characteristics. By varying the orientationof the webs from support tube to support tube, the overall supportprofile of the sole can be controlled.

In one embodiment, the support layer is disposed between the outsole andthe midsole. If desired, the sole may further include a heel wedgedisposed between the outsole and the insert in the heel region. The heelwedge may be manufactured from a material that is firmer than themidsole material. As a result, the heel wedge may provide additionalsupport in the heel region of the sole.

In another embodiment, the insert may include a plurality of supporttubes on the medial (or inner) side of the sole and a plurality ofsupport tubes on the lateral (or outer) side of the sole. The internalwebs may be disposed in a more vertical orientation along the medialside of the sole to provide greater vertical support on the medial sideof the sole. If desired, the orientation of the webs can vary from tubeto tube. For example, the webs may be oriented in an increasingly morevertical direction moving from front to rear to provide increasinglymore vertical support toward the rear of the heel. The support tubes onthe medial side may be connected to the support tubes on the lateralside by struts. The struts may be concave to provide the heel with aninherent centering capability.

In yet another embodiment, the support tubes are disposed in at least aportion of the heel region of the insert and the insert includes an archportion extending through the arch region of the sole. The arch portionof the insert may include two layers spaced apart from one another toprovide a structure to receive a gaiter strap. The lower layer helps toprotect the gaiter strap from damage associated with ground contact. Ifdesired, the insert may further include a forefoot extension thatextends through at least a portion of the forefoot region of the sole.The forefoot extension may extend only along the medial side of theforefoot region to provide a sole that is more rigid along the medialside. The forefoot extension may extend through different regions of theforefoot or may cover the entire forefoot region, as desired.

In another embodiment of the present invention, the insert includes aplurality of front support tubes. In one embodiment, the front supporttubes are positioned in the forefoot region and extend across theforefoot region from the medial side to the lateral side of the sole.The front support tubes may be arranged in a radiating pattern such thatthey diverge as they approach the lateral edge of the sole. In anotherembodiment, the front support tubes are formed from a first materialthat forms a base, and a second material that extends upwardly from thebase and has a lower durometer value than the first material.

The present invention provides a unique footwear sole that can be easilytuned to provide the desired support profile. The insert may bemanufactured from TPU or other relatively durable materials that do notdegrade as quickly as conventional foam materials and therefore extendthe cushioning life of the midsole. The support profile may be variedbetween the medial and lateral sides of the sole. For example, thesupport tubes on the medial side of the sole can be tuned to provideincreasing vertical stiffness toward the back of the shoe, therebyaddress the problem of overpronation. The insert is relativelyinexpensive to manufacture and its support characteristics can bereadily adjusted by controlling, among other things, the nature andorientation of the support tubes and the webs. The insert can becombined with a heel wedge to provide even greater control over itssupport profile. The arch portion of the insert can be tuned to providecontrol over the support profile of the sole in the arch region. Thegaiter slot can be incorporated into the arch portion to protect agaiter strap from premature wear. The support profile of the sole in theforefoot region can be controlled through the use of the forefootextension. When included, the struts assist in centering the foot onheel strike. The front support tubes enable controlled cushioning in theforefoot regions and can be arranged in proper alignment for anefficient toe-off.

These and other objects, advantages, and features of the invention willbe readily understood and appreciated by reference to the detaileddescription of the preferred embodiment and the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded perspective view of a sole in accordance with anembodiment of the present invention.

FIG. 2 is a medial side elevational view of the shoe.

FIG. 3 is a side elevational view of the midsole.

FIG. 4 is a top plan view of the midsole.

FIG. 5 is a bottom plan view of the midsole.

FIG. 6 is a top plan view of the insert.

FIG. 7 is a bottom plan view of the insert.

FIG. 8A is a right (medial) side elevational view of the insert.

FIG. 8B is a left (lateral) side elevational view of the insert.

FIG. 9 is a side elevational view of the heel wedge.

FIG. 10 is a bottom plan view of the insert and midsole.

FIG. 11 is a bottom plan view of the insert, midsole and heel wedge.

FIG. 12 is a bottom plan view of the shoe.

FIG. 13 is an exploded perspective view of a sole in accordance withanother aspect of the present invention.

FIG. 14 is a top view of the insert according to the second embodiment.

FIG. 15 is a medial side view of the insert according to the secondembodiment.

FIG. 16 is an exploded perspective view of the insert according to thesecond embodiment.

FIG. 17 is a lateral side view of the insert according to the secondembodiment.

DETAILED DESCRIPTION OF THE CURRENT EMBODIMENTS

A footwear sole manufactured in accordance with an embodiment of thepresent invention is shown in FIG. 1, and generally designated 10. Thefootwear sole 10 generally includes an outsole 12, a heel wedge, 14, aninsert 16 and a midsole 18. The sole 10 may be incorporated into anarticle of footwear, such as shoe 200 shown in FIG. 2. The shoe 200 mayinclude an upper 202 that is affixed to the sole 10. The shoe 200 mayalso include a footbed (not shown) that is removably fitted into theupper 202 atop of the sole 10. The insert 16 may include support tubes46 a-j with internal webs 48 a-j that are configured to control thesupport profile of the sole 10. Although the present invention isdescribed in connection with a conventional standard height running ortrail running shoe 200, the present invention is not limited to use inshoes of that type. The present invention is well-suited for use inessentially any type of sole and can be incorporated into essentiallyany type of footwear. The footwear sole 10 is intended to be secured toan upper (not shown) using essentially any attachment construction,including without limitation cement, stitch, welt and direct attachconstructions. The footwear sole 10 may also include a shank or otherconventional sole components, as desired.

To facilitate disclosure of the present invention, reference will bemade to various general areas of the foot, such as the heel, arch andforefoot areas. When used to refer to locations on the various solecomponents, these terms should be interpreted to include those areas ofthe sole that are disposed generally (and not necessarily directly)beneath the corresponding elements of the foot. For purposes of generalreference only, the heel area is generally defined as that area behind(toward the rear of the heel of the sole 10) phantom line A1 (See FIG.2), the arch area is generally defined as that area between phantomlines A1 and A2 and the forefoot region is generally defined as thatarea ahead of (toward the tiptoe of the sole 10) phantom line A2. Itshould be understood, however, that the boundaries between the heel,arch and forefoot areas are not precise and that these terms should beinterpreted loosely and with a great deal of flexibility.

In the described embodiment, the outsole 12 is generally conventionaland defines the primary wear surface for the sole 10. The outsole 12 isgenerally conventional and is secured to the bottom of the sole 10 toprovide a durable and non-slip wear surface (See FIG. 2). The design andconfiguration of the outsole 12 may vary fromapplication-to-application. However, in the illustrated embodiment, theoutsole 12 is a two-piece outsole having a main part 20 and heel part 22(See FIGS. 1 and 12). The main part 20 of this embodiment extends acrossportions of the heel wedge 14, insert 16 and midsole 18. The main part20 is cemented or otherwise secured to the bottom of the various solecomponents 14, 16 and 18 using generally conventional techniques andapparatus. The heel part 22 is disposed at the back of the heel and iscemented to the undersurface of the heel wedge 14 using generallyconventional techniques and apparatus. Separation of the main part 20and the heel part 22 provides the outsole 12 with a degree ofarticulation in the heel. The lower surface of each part 20 and 22includes a plurality of lugs or other traction elements, which aregenerally identified in the drawings by reference numeral 24. The designand configuration of the traction elements 24 may vary from applicationto application as desired. The outsole 12 may be manufactured from awide variety of conventional sole materials, such as natural andsynthetic rubbers, leather, PVC, EVA and polyurethane.

As noted above, the sole 10 includes a heel wedge 14 disposed above theoutsole 12 in the heel region (See FIGS. 1 and 2). The heel wedge 14provides a resilient, compressible platform for the insert 16 asdescribed in more detail below. Referring now to FIG. 9, the heel wedge14 is generally wedge-shaped having an upper surface 26 that iscontoured to compliment the shape of the bottom surface 30 of the insert16 and a lower surface 32 that is contoured to compliment the shape ofthe upper surface 34 of the outsole 12. More specifically, the uppersurface 26 of the illustrated embodiment includes a plurality of tuberecesses 36 a-j that corresponds in shape with the support tubes 46 a-j.The tube recesses 36 a-j closely receive the support tubes 46 a-j in theassembled sole 10. The heel wedge 14 may be manufactured from a varietyof sole material, such as EVA and polyurethane. In the illustratedembodiment, the heel wedge 14 defines a central opening 80 that isaligned with a corresponding absence of material in the heel region ofthe outsole 12. Among other things, the opening 30 permits viewing ofportions of the midsole 16 and insert 18. As perhaps best shown in FIG.11, the heel wedge 14 may include an arrangement of small ridges 86 onits undersurface 88 that, among other things, provide a guide forplacing the outsole 12 parts. In the illustrated embodiment, the heelwedge 14 extends only through the heel region of the sole 10 and isgenerally wedge-shaped. The heel wedge 14 may extend through differentregions of the sole and may, for example, extend through the arch regionor be coextensive with the entire sole. The heel wedge 14 is notnecessarily wedge-shaped and may take on different thicknessconfigurations as desired. In the illustrated embodiment, the heel wedge14 is manufactured from EVA foam having a durometer value ofapproximately 55-60 Asker C Scale. The type of material and density ofthe heel wedge 14 material may, however, vary from application toapplication. If desired, the density of the heel wedge 14 may vary fromregion to region within the heel wedge 14.

The insert 16 is disposed above the outsole 12 and the heel wedge 14,and provides the sole 10 with a highly tuned support profile (See FIGS.1 and 2). Referring now to FIGS. 6, 8, 8A and 8B, the insert 16generally includes a heel portion 40, an arch portion 42 and a forefootextension 44. The heel portion 40, as its name implies, extends throughat least a portion of the heel region of the sole 10 and includes aplurality of support tubes 46 a-j. In the illustrated embodiment, thesupport tubes 46 aj extend in a generally lateral orientation. Theinsert 16 may include a first plurality of support tubes 46 a-eextending through a peripheral marginal portion of the lateral side ofthe heel region (“lateral support tubes”) and a second plurality ofsupport tubes 46 fj extending through a peripheral marginal portion ofthe medial side of the heel region (“medial support tubes”). The medialsupport tubes 46 fj and lateral support tubes 46 a-e may be spaced apartso that the support tubes 46 aj do not extend through the central regionof the sole 10. The absence of support tubes 46 aj in the central regionmay provide a relatively soft center that helps to center the wearer'sfoot on the sole 10. The use of separate medial and lateral supporttubes is not strictly necessary, and in some applications, the supporttubes may be located only on one side or may extend entirely across thesole 10. In the illustrated embodiment, the support tubes 46 aj aregenerally annular in cross-section. The support tubes 46 aj mayalternatively have other cross-sectional shapes (both regular andirregular), such as oval, square, rectangular and triangular. Thecharacteristics of each support tube 46 aj may be varied to control itsparticular response to different loads. For example, the number, shape,diameter, length and wall thickness of the support tubes 46 aj may bevaried to tune the support characteristics of the sole 10. Each supporttube 46 a-j may also include an internal web 48 a-j that affects thesupport characteristics of the tube 46 a-j. In the illustratedembodiment (where the support tubes 46 a-j are generally annular incross-section), the webs 48 a-j are chords, and more particularly extendalong diameters of the support tubes 48 a-j. But, the characteristics ofeach web 48 a-j may be varied to control its affect on the supportcharacteristics. For example, the number, orientation, position, lengthand thickness of the webs 48 a-j can be varied. In the illustratedembodiment, the lateral support tubes 46 a-e each include a web 48 a-ethat extends in a generally horizontal direction following the generalextent of the insert 16. Accordingly, the webs 48 a-e have little affecton the rigidity of the lateral support tubes 46 a-e in the verticaldirection. In the illustrated embodiment, the orientation of the webs 48fj of the medial support tubes 46 fj varies from front to rear. Morespecifically, the medial webs 48 f-i are arranged at a more verticalorientation toward the rear of the heel region as can be seen in FIGS. 2and 8A. As a result, the medial support tubes 46 fj provide increasinglymore resistance to vertical compression toward the rear of the heelregion. In the illustrated embodiment, the webs 48 a-j are integrallyformed with the support tubes 46 aj. This is not, however, strictlynecessary and the webs 48 aj may alternatively be separatelymanufactured, for example, as inserts that are fitted into the supporttubes 46 a-j.

The insert 16 may also include a plurality of struts 38 a-d that jointhe support tubes 48 a-d on one side of the sole 10 with the supporttubes 48 f-I on the opposite side. The characteristics of the struts 38a-d may be varied to control the support characteristics of the sole 10.For example, changes in the number, width, thickness and shape of thestruts 38 a-d will impact the support characteristics of the insert 16.As shown, the struts 38 a-c are of this embodiment are generally concaveto follow a convex structure on the undersurface of the midsole 18. Inthis embodiment, the struts 38 a-c are concave primarily to accommodaterecess 64 and plug 62.

The arch portion 42 of the illustrated embodiment is integral with andextends from the heel portion 40. It may alternatively be a separatecomponent. The arch portion 42 includes a pair of wings 50 a-b thatextend upwardly from its lateral and medial edges. The wings 50 a-b maybe cemented or otherwise secured to the midsole 18. In use, the wings 50a-b provide the midsole 18 with enhanced support in the arch region. Thearch portion 42 may also define a slot 52 for receiving the strap of agaiter. The arch portion 42 of the illustrated embodiment includes apair of spaced apart layers 54 a-b that cooperatively define the slot52. The size, shape and configuration of the layers 54 a-b may vary fromapplication to application as desired. The arch portion 42 is optionaland may be eliminated, if desired.

The forefoot extension 44 of the illustrated embodiment is integral withand extends from the arch portion 42. It may alternatively be a separatecomponent. The forefoot extension 44 may extend only along a peripheralportion of the medial side of the sole 10 (as shown in the illustratedembodiment). It may, however, be designed to extend through essentiallyany portion of the forefoot region or over the entire forefoot region,if desired. The forefoot extension 44 may define a plurality of flexslots 56 a-c configured to provide flex points. The forefoot extension44 is optional and may be eliminated in some applications, as desired.

The insert 16 may be manufactured from a variety of conventionalmaterials, but typically it will be manufactured from a material that isstiffer than the heel wedge 14 and/or midsole 18. For example, theinsert 16 may be injection molded from TPU, TPR or PVC. The insert 16may be manufactured from other materials, such as nylon, rubber,synthetic rubber or silicone, but it is likely that the insert 16 wouldnot be manufactured by injection molding if any of these alternativematerials was used. If desired, the insert 16 may be manufactured from acollection of different materials. For example, the arch portion 42 maybe manufactured from a stiffer material than the heel portion 40.

In the illustrated embodiment, the support tubes 46 a-j extend onlythrough the heel region of the sole 10. In alternative embodiments, thesupport tubes 46 a-j may in addition (or alternatively) extend throughthe arch and/or forefoot regions of the sole. The size, configuration,layout and other characteristics of the support tubes 46 a-j may varyfrom region to region and from application to application.

The midsole 18 is disposed between the insert 16 and the upper 202, andis designed to provide a compressible, resilient foot platform (SeeFIGS. 1 and 2). As it is designed to support the foot and to beincorporated into conventional footwear, the midsole 18 is generallyfoot-shaped. The midsole 18 may, however, take on other shapes, asdesired, to accommodate various alternative sole designs. In theillustrated embodiment, the midsole 18 is manufactured from EVA foamhaving a durometer value of approximately 55-60 Asker C Scale. The typeof material and density of the midsole 18 material may, however, varyfrom application to application. In the illustrated embodiment, themidsole 18 is a one-piece, unitary structure, but it may alternativelyinclude a collection of separate elements that cooperatively support thefoot. For example, in an alternative embodiment, the midsole 18 mayinclude a forefoot segment that is manufactured from a relatively softmaterial and heel region manufactured from a more rigid material. Themidsole 18 includes a generally smooth upper surface 60 designed tosupport the wearer's foot (See FIG. 4). The upper surface 60 may includecontours, if desired. For example, the upper surface 60 of the midsole18 may be contoured to match the natural contours of the wearer's foot,for example, by providing the upper surface 60 with a concave heel area,a raised arch area or essentially any other desired shape. The midsole18 of the illustrated embodiment includes a peripheral lip 68 thatextends upwardly around the peripheral edge of the midsole 18. Themidsole 18 may directly engage the undersurface of the wearer's foot. Inmost applications, however, an additional component (not shown) will beincorporated into the sole 10 above the midsole 18. For example, aninsole (not shown), sock liner (not shown), footbed (not shown) or othersole element may be incorporated into the sole 10 above the midsole 18.This additional component may be removably fitted into the shoe 200 atopthe sole 10.

In the illustrated embodiment, the midsole 18 includes a disc-shapedplug 62 that is fitted into a corresponding recess 64 in the heel area(See FIG. 1). The plug 62 is manufactured from a relatively softcushioning material, such as closed cell foam. In the illustratedembodiment, the plug 62 is manufactured from a material having a lowerdensity than the material of the midsole 18. As a result, the plug 62and recess 64 combination help to center the foot in the heel of thesole 10. The size, shape and configuration of the plug 62 and recess 64may vary from application to application. For example, the plug 62 andrecess 64 combination may be replaced by one or more perforations orcutouts that reduce the resistance of the corresponding region tocompression. In this embodiment, the recess 64 is vertically alignedwith the convex region of the struts, but that is not strictlynecessary.

The midsole 18 may be configured to provide ventilation as shown in theillustrated embodiment. In this embodiment, the midsole 18 defines aplurality of ventilation holes 70 through the sidewall of the midsole 18and a series of ventilation channels 72 in the upper surface 60 of themidsole 18 (See FIG. 4). The ventilation channels 72 communicate withthe ventilation holes 70 to permit air and water to ventilate throughthe midsole 18 (See FIG. 3). Again, this is optional and the presentinvention may be incorporated into a non-ventilated midsole as desired.

Referring again to FIG. 4, the midsole 18 may also include a pluralityof flex grooves 74 a-c to facilitate flexing of the midsole 18. In theillustrated embodiment, the midsole 18 includes flex grooves 74 a-cextending substantially laterally across the sole 10 in the forefootregion. If desired, the flex grooves 74 a-c may be eliminated orreplaced by other structure intended to improve flexibility. Forexample, the flex grooves 74 a-c may be replaced by a relatively shallowrecess (not shown) in the top surface of the midsole 18 that is filledwith a pad (not shown). The pad may have a lower density than thematerial of the midsole 18. The pad may be cemented within the recess.

The undersurface 66 of the midsole 18 may be contoured to compliment theshape of the outsole 12, heel wedge 14 and insert 16 (See FIG. 5). Inthe illustrated embodiment, the undersurface 66 of the midsole 18 iscontoured to define a plurality of support tube recesses 78 that areadapted to closely receive the support tubes 46 a-j of the insert 16. Ifdesired, an insert recess 76 may be defined in the undersurface 66 sothat the insert 16 can be recessed or inset into the midsole 18. Forexample, the midsole 18 may define a plurality of strut recesses 82adapted to receive the struts 38 a-d of the insert 16. The recess 76 mayalso extend through the extents of the arch portion 42 (including thewings 50 a-b) and forefoot extension 44. Alternatively (or in addition),recesses (not shown) may be formed in the top surface of the outsole 12to receive all or a portion of the insert 16.

The midsole 18 and heel wedge 14 are separate components in theillustrated embodiment. The present invention extends, however, toapplications in which the midsole and heel wedge are integral. Forexample, in an alternative embodiment, the appropriate material (e.g.EVA foam) may be injected or poured into a mold about the insert toentrap the insert in a single piece midsole/heel wedge combination.

Alternative Embodiment

An alternative embodiment of the footwear sole of the present inventionis shown in FIGS. 13-17, and generally designated 100. In thisembodiment, the insert 160 includes a plurality of forefoot supporttubes 510 a-e. Similar to the first described embodiment, the insert 160is disposed above the outsole 120 and the heel wedge 140, and providesthe sole with a highly tuned support profile in the forefoot region.Referring now to FIGS. 14-17, the insert 160 may include a heel portion400, an arch portion 420 and a forefoot portion 440. The heel portion400 is generally the same as the heel portion 40 described in connectionwith the first embodiment, and therefore will not be described again indetail. Suffice it to say that the heel portion 400 may include supporttubes 460 a-j including internal webs, and struts 380 a-d. Similarly,the arch portion 420 is generally the same as the arch portion 42described in connection with the first embodiment. The arch portion 420includes a pair of wings 500 a-b that extend upwardly from its lateraland medial edges. The wings 500 a-b include a plurality of holes 502extending therethrough. The arch portion 420 may also define a slot 520for receiving the strap of a gaiter—as shown, the slot 520 is formed byfirst and second layers 540 a-b. The slot 520 may be oval in shape asillustrated, however, the slot 520 may have a variety of shapes. Boththe arch portion 420 and the heel portion 400 are optional and may beeliminated, if desired.

In the illustrated embodiment, the forefoot portion 440 of thealternative embodiment is integral with and extends from the archportion 420. It may alternatively be a separate component, or the onlycomponent if the heel portion 400 and/or the arch portion 420 areeliminated. A plurality of forefoot support tubes 510 a-e are providedin the forefoot portion, or at least at a position in front of the archregion. In the illustrated embodiment, three of the central forefootsupport tubes 510 b-d extend laterally all the way across the insert160, and a peripheral two of the forefoot support tubes 510 a and 510 eextend from the lateral side of the insert 160 partially across theinsert 160 where they converge to a point at a closed end 530.Functionally, these two support tubes 510 a and 510 e are stiffer at theclosed end than they are at the open end. The forefoot support tubes maybe positioned in a radiating arrangement, to enable an efficient toe-offtowards the medial side of the shoe 100. As illustrated, forefootsupport tubes 510 c and 510 d are positioned in a radiating arrangement,such that they diverge as they extend from the medial side to thelateral side of the insert 160. Alternatively, more than two of theforefoot support tubes 510 a-e may be arranged radially, or in anotherarrangement.

As shown in FIGS. 16 and 17, in one embodiment, the forefoot supporttubes 510 a-e each include a generally flat base 550 a-e, and agenerally semi-circular wall 570 a-e extending upwardly from the base550 a-e and forming a tube. The upwardly extending walls 570 a-e mayalternatively have a variety of shapes. They may be hollow, as shown, ormay be filled with a support material, such as EVA. In anotherembodiment, the bases may have different shapes, for example, they maybe semi-circular to form round tubes. In yet another embodiment, thewalls may extend downwardly from the base, or both upwardly anddownwardly from the base.

The bases 550 a-e of each forefoot support tube 510 may be integrallyconnected to each other and to the arch portion 420, for example, as aforefoot extension of the insert 160. As shown, the bases 550 a-e areintegrally connected to each other to form a web 590 extending from thearch portion 420. The web 590 is cut off just in front of the forwardmost forefoot support tube 510 a. It may, however, be designed to extendthrough essentially any portion of the forefoot region or over theentire forefoot region, if desired. Alternatively, one or more of thebases and forefoot support tubes may be separate sections. As shown, theweb 590 additionally integrally includes a peripheral portion of each ofthe upwardly extending walls 570 a-e. Referring to FIGS. 14 and 16, afirst set of loops 610 a-e extend upwardly from the web 590 to form afirst peripheral portion of the forefoot support tubes 510 a-e on thelateral side of the insert 160. A second set of loops 630 a-c extendupwardly from the web 590 to form a second peripheral portion of theforefoot support tubes 510 a-e on the medial side of the insert 160. Theweb 590 may additionally define a plurality of flex slots 560 configuredto provide flex points. As in the first embodiment, the insert 160 canbe attached to the outsole 120 by a variety of conventional methods.

The insert 160, including the forefoot support tubes 510 a-e, may bemanufactured from a variety of conventional materials, but typically itwill be manufactured from a material that is stiffer than the heel wedge140 and/or midsole (not shown). For example, the insert 160 may beinjection molded from TPU, TPR, PVC or other injected polymers. Theinsert 160 may be manufactured from other materials, such as nylon,rubber, synthetic rubber or silicone, but it is likely that the insert160 would not be manufactured by injection molding if any of thesealternative materials was used. If desired, the insert 160 may bemanufactured from a collection of different materials. For example, thearch portion 420 may be manufactured from a stiffer material than theheel portion 400.

Referring now to FIG. 16, in one embodiment, the forefoot support tubes510 a-e are formed from two different materials. The web 590, includingbase portions 550 a-e and the first and second sets of loops 610 a-e and630 a-c, are formed from a first material. The upwardly extending walls570 a-e are formed from a second material. In the illustratedembodiment, the upwardly extending walls 570 a-e are connected togetherby an upper web 650, such that they may be formed from a single piece ofthe second material. As illustrated, all of the insert 160 except forthe upwardly extending walls 570 a-e is formed from the first material.The second material is typically softer than the first material, suchthat the forefoot support tubes 510 a-e provide the desired level ofcushioning and support. In one embodiment, the first material has adurometer value of 85 Shore A, and the second material has a durometervalue of 65 Shore A. In another embodiment, the first material isapproximately 10-30 Shore A points higher than the second material,however, the range may vary, and alternatively the first material may besofter than the second material. If desired, the forefoot support tubesmay be formed from more than two materials, for example, the walls 570a-e may each be formed from a different material with a differentdurometer value in order to even more closely control the support andcushioning characteristics of the insert 160. The second material may beattached to the first material by a variety of conventional methods,such as cement, adhesive, or bonding by heating one or both of thematerials.

Although not shown, in this embodiment, the midsole is similar to themidsole 18 of the first embodiment. The undersurface of the midsole maybe contoured to compliment the shape of the outsole 120, heel wedge 140and insert 160—including the forefoot support tubes 510 a-e, as in thefirst embodiment, such the midsole is contoured to define a plurality ofsupport tube recesses that are adapted to closely receive the supporttubes 460 a-j and the forefoot support tubes 510 a-e of the insert 160.The midsole may include a plug, similar to the plug 62 of the firstembodiment. The heel wedge 140 is also similar to the heel wedge of thefirst embodiment, and will not be described in detail. As in the firstembodiment, the heel wedge may include tube recesses 360, and a centralopening 800.

The above description identifies certain approximate durometer valuesfor the various components of the sole 10 of the illustrated embodiment.The recited values are merely exemplary and the present invention is notlimited to sole constructions with the specific recited durometervalues. To the contrary, the present invention should be broadlyinterpreted to extend to sole components having differentcompressibility values.

The above description is that of the current embodiments of theinvention. Various alterations and changes can be made without departingfrom the spirit and broader aspects of the invention as defined in theappended claims, which are to be interpreted in accordance with theprinciples of patent law including the doctrine of equivalents. Anyreference to claim elements in the singular, for example, using thearticles “a,” “an,” “the” or “said,” is not to be construed as limitingthe element to the singular.

1. An article of footwear comprising: a two-component insert including aplurality of resilient compressible front support tubes, each of saidfront support tubes defining a base, and a wall extending from saidbase, wherein said base is formed from a first material, and said wallis formed from a second material softer than said first material, and;an outsole positioned below said insert and forming a ground engagingwear surface for the article of footwear.
 2. The article of footwear ofclaim 1 wherein said insert includes a lateral side and a medial side,and wherein at least two of said front support tubes are arranged in aradiating pattern such that they diverge as they extend from said medialside towards said lateral side.
 3. The article of footwear of claim 2wherein said insert includes a forefoot portion, said front supporttubes positioned in said forefoot portion.
 4. The article of footwear ofclaim 1 wherein said bases of each of said support tubes are connectedto form a forefoot web, said forefoot web formed from said firstmaterial.
 5. The article of footwear of claim 1 wherein said insertincludes an arch portion and a heel portion, said heel portion includinga plurality of resilient compressible rear support tubes, each of saidrear support tubes defining an internal void; and a plurality of webs,each of said webs being disposed within a corresponding one of said rearsupport tubes and extending at an orientation, said orientation of eachof said webs being pre-selected to provide said insert with a supportprofile.
 6. The article of footwear of claim 1 wherein said frontsupport tubes include a first end and a second end, at least one of saidfirst and second ends of each of said front support tubes being open. 7.The article of footwear of claim 6 wherein at least one of said firstand second ends of at least one of said front support tubes is closed.8. The article of footwear of claim 6 wherein at least one of said firstand second ends of each of said front support tubes includes a generallyflat base and a generally semi-circular wall extending from said base.9. The article of footwear claim 1 wherein said plurality of frontsupport tubes includes at least one central support tube and at leasttwo peripheral support tubes on opposite sides of said at least onecentral support tube, said at least one central support tube extendingsubstantially across the lateral extent of said insert, said peripheralsupport tubes extending from the lateral side of said insert onlypartially across said insert.
 10. An article of footwear having aforefoot region, the article of footwear comprising: a two-componentinsert permanently affixed in the article of footwear, said insertincluding a lateral side, a medial side and a plurality of resilientcompressive front support tubes, said front support tubes positioned inthe forefoot region of the article of footwear and extending laterallyacross at least a portion of said insert, at least two of said frontsupport tubes positioned in a radiating arrangement such that said atleast two of said front support tubes diverge as they extend toward saidlateral side of said insert, each said support tube including a basecomprised of a first material and a wall extending from the base andformed from a second material, said second material being softer thansaid first material; a cushioned midsole disposed above said insert; andan outsole disposed below said insert and forming a wear resistant,ground engaging surface of the article of footwear.
 11. The article offootwear of claim 10 wherein said plurality of front support tubesinclude at least one central front support tube, and at least oneperipheral front support tube, said central front support tube extendingsubstantially across said insert, said peripheral front support tubeextending partially across said insert.
 12. The article of footwear ofclaim 11 wherein at least one of said front support tubes has asemi-circular cross section.
 13. The article of footwear of claim 11wherein said at least one peripheral front support tube extends from anopen end adjacent to said lateral side of said insert to a closed endpartially across said insert.
 14. The article of footwear of claim 11wherein said at least one peripheral front support tube tapers to apoint at said closed end.
 15. An article of footwear having a forefootregion, the article of footwear comprising: an upper; an outsole havinga ground engaging surface and an upper surface; and an insert betweensaid upper and said outsole, said insert positioned in the forefootregion of the article of footwear, said insert including a base formedfrom a first material, and a plurality of support tube walls attached tosaid base and extending upwardly from said base, said plurality ofsupport tube walls formed integrally with each other from a secondmaterial that is softer than said first material.